Title of Invention

METHODS AND APPARATUS FOR MAKING PARTICLES USING SPRAY DRYER AND IN-LINE JET MILL

Abstract metheds and appuratur are privided for making particles comparsing (1) spraying an emulstion solution or sos- pension, which comprise a solvent and a bult inulcnal (e.g., a phannaceuiletal agent). thought all atulpizer(14) and into a primary Urving chamber (12) having a drying gas following therthrough, to from droplets comprising the solvent and bulk matchal dispersed in the drying gas (b) eraporning, in the primary draying chamber (12), an loast a portion of the solvem into the drying gas to solidify the droplets and rorm paricles dispersed in draying gas and flowing the partiles and of least a portion or the drying gas though a jet mill (24) to deageglomerate or grind the parthcles. By coupling spray drying with "in-line" jet milling, a single step process is ereaied from two separate unit openations. and an additional colletion step is advanlagcosty climtred. The one-step, in-line process has further advanges in utsc and cost of proccessing.
Full Text
METHODS AND APPARATUS FOR MAKING PARTICLES USING
SPRAY ORYER AND IN-LINE JET MILL
Background of the Invention
5 This invention is generally in the field of process equipment and methods for
making particles, and more particularly to meihods of deagglomerating or grinding
spray dried particles.
Spray drying is commonly used in the production of particles for many
applications, including Pharmaceuticals, food, cosmetics, fertilizers, dyes, and
10 abrasives. Spray drying can be tailored to create a wide spectrum of particle sizes,
including microparticles. Spray dried particles are useful is in variety of biomedical and
pharmaceutical apphcation, such as the deliver of therapeutic and diagnostic agents,
as described for example in U.S. Patent No. 5,853,698 to Straub et al.; U.S. Patent No.
5,855,913 to Hanes et al.; and U.S, Patent No, 5,622,657 to Takada et al. For these
15 applications: microparticles having very specific sizes and size ranges often are needed
in order to effectively deliver the active agents.
particles may tend in agglomerate during their production and processing,
therehy undesirably astrering the effective size of the particles, to the detriment or the
particle formulation's perfomance and/or reproducibility- In other circumstances, the
20 particles made may simply be larger than desired for a particular application
Therefore, after they are produced, particles may require additional processing for size
reduction and/or deagglomeration.
In one common appmach, sepsrate bstch process steps are ussed, For example,
particles are made by a known sptay drying process, collected, and then ground in a
25 second, separate step. Such a batch method, however, undesirably requires the use of a
tranafer step from the spray dryer to the mill, which, for an aseptic process, mey be
difficult to perform. Such a batch process also requires two separate collection steps
that are both associated with a yield loss. It would be desirable to provide a sterile
particle production and milling process and to mimimize product yield losses, reduce
30 material transfer steps, reduce process time, and reduce production costs, In addition,
laboratory scale methods for producing microparticle pharmaceutical formulations may
require several steps, which may not be readily or efficiently ttansferred to larger scale
production, It would be desirable for the microparticle production and deagglomeration
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(or grinding) process to be adaptable for efficient, tost effective, commercia scale
production.
Summray of the Invention
5 Methods and apparatus are provided for meking particles in an in-inline process.
comprising: (a) spraying on emusion, solution, or suspension, which comprises a
solvent and a bulk material through an atomizer and into a primary drying chamber
having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrough, to
form droplets comprising the solvent and the hulk material, wherem the dioplete are
10 dispensed in the drying gas; (b) evaporating, in the primary drying chamber, at least a
portion of the solvent into the drying gas to solidify the droplets and form particles
dispersed in the drying gas, the particles dispersed in the drying gas being a feedstream;
and (c) flowing the particles of the feedstream through a jet mill to deagglomerate or
grind the particles. This process using spray drying coupled with "in-line" jet miliing
15 eliminates an aseptic transfer from the spray dryer to the jet mill (which would be
particularly important for making pharmaceutical formulations comprising the
particles) and an additional collection step that would be associated with a yield loss.
The inline process can effectively cut processing time by at least one half compared to a
two step process.
20 In a preferred embodiment of the method, step (c) is condueted to
deagglomaerate at least a portion of agglomerated particles, if any, while subscautjally
maintaining the size and morphology of the individual particles. Altermativety, step (c)
can be conducted to grind the particles.
Preferably, the feedsceam of step (b) is directed dirough a particle coccentration
25 means to separate and remove at least a portitai of the drying gas from the feedstream.
In ons embodiment, the particle concentration means comprises a cyclone separator. In
one embodiment, the cyclone separates between about 50 and 100 vol.% of the drying
gas from the particles.
In one embodiment of the method, the feedsteam of step (b) is directed, before
30 step (c), through at least ant secondary drying chamber in fluid commumcarion with the
discharge outlet of the primary drying chamber to evpporate a second portion of the
solvent into the drying gas. In a preferred embodiment, the secondary drying chamber
comprises tubing having an inlet in fluid communication with the discharge outlet of
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the primary drying chamber, wherein the ratio of the cross-sectional area of the primary
drying chamber to the cross-sectional area of the tubing is at least 4.3, and whetiein the
ratio of the length of the tubing to the length of the primary drying chamber is at least
2:1.
5 In another embodiment of the method, multiple nozzles are used in step (a) to
introduce multiple emulsions, solutions, suspensions, or combinations thereof.
In one embodiment, the bulk material comprises a pharmaceutical agent. The
pharmaceutical agent may be a therapeutic, a prophylactic, or a diagnostic agent. In one
embodiment, the therapeutic or prophylactic agent comprises a hydrophobic drug and
10 the particles are microspheres having voids or pores therein, In another embodiment,
the bulk material comprises a diagnostic agent, such as an ultrasound contrast agent or
another agent for diagnostic imaging. In another embodiment, the bulk material further
comprises a shell forming material, such as a polymer (e.g,, a biocompatible synthetic
polymer), a tipid, a sugar, a protein, an amino acid, or a combination thereof.
15 In a preferred embodiment, the particles are microparticles, In one embodiment,
the microparticles comprise microspheres having voids or pores therem.
In one smbodiment, the bulk material comprises a therapeutic or prophylactic
agent. In one embodiment, the therapeutic or prophylactic agent comprises a
bydrophobic drug and the particles are microspheres having voids of pores threin, In
20 another embodiment, the bulk material comprises a diagnostic agent, such as an
ultrasound contrast agent or other agent for diagnostic imaging.
In one embodiment, the method further comprises adding an excipient material
Or pharmaceutical agent to the feedstream of step (b). For example, this could be done
after the feedstream has flowed through a particle concentration means to separate and
25 remove at least a portion of the drying gas from the feedstream, In another example,
this could be done before the feedstream has flowed through a particle concentration
means to separate and remove at least a portion of the drying gas from the feedstream,
In a preferred embodiment, the excipient or pharmaceutical agent is in the form of a dry
powder, Examples of the excipient material include amimo acids, proteins, polymers,
30 carbohydrates, starclies, surfactant, and combinations thereof
In another aspect, a method is provided for making a dry powder blend. The
method includes the steps of (a) spraying an emulsion, solution, or suspension, which
comprises a solvent and a bulk material, (trough an atomizer and into a primary drying
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chamber having a trying gas inlet, a discharge outlet, and a drying gas flowing
therethrough, to form droplets comprising the solvent and the bulk material, therein
the droplets are dispensed in the drying gas; (b) evaporating, in the primary drying
chamber, at least a. portion of the solvent into the drying gas to solidify the droplets and
5 form particles dispersed in the diying gas, the particles dispersed in the drying gas being
a feedstream; (c) adding a dry powder excipient material to the feedstream to farm a
blended feedstream; and (d) flowing the particles and excipient material through a jet
mill to deagglomcrate or grind the particles and excipientmaterial. Preferably, the
method includes directing the feedstream of step (b) through a particle concentration
10 means to separate and remove at least a portion of the drying gas from the feedstream.
In one embodiment, the particles are microparticles comprising a pharmaceutical agent
and the excipient material is in the form of microparticles having a size that is larger
than the size of the microparticles comprising a pharmaceutical agent. In a preferred
embodiment, step (d) is conducted to deaggtomerate at least a portion of agglomerated
15 particles if any, while substantially maintaining the size and morphology of the
individual particles. In another embodiment, a second pharmaceutical agent can be
added in step (c) in place of or in addition to the exoipient.
In another aspect, an apparatus is provided for making particles and
deagglomenrating or grinding them. in a prefered embodiment, the apparatus
20 comprises: (a) an atomizer disposed for spraying an emulsion, solution, or suspension
which comprises a solvent and a bulk material to form droplets of the solvent and the
bulk material; (b) a primary drying chamber having a diyjng gas inlet and a discharge
outlet, the stomizer being located, in the primary drying chamber which provides for
evaporation of at least a portion of the solvent into the drying gas to solidify the
25 droplets and form particles dispensed in the drying gast and (c) a jet mill having in intel
in fluid communication with the discharge outlet paimary drying chamber, the jet mill
being operable to reoeive the particles dispersed in at least a portion of the drying gas
and grind or deaggiomerate the particles.
In one embodiment, the apparatus further includes at least one secoridary drying
30 chamber interposed between, and in fluld communication with, the discharge outlet of
the primary drying chamber and the inlet of the jet mill, which provides additional
drying of the particles, i,e, provides tor evaporation of a second portion of the solvent
into the drying gas, In one version, the seconnaiy drying chamber comprises tubing
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having an inlet in fluid communication with the discharge outlet of the primary drying
chamber, wherein the ratio of the cross-sectiooal area of the primary drying chamber to
the cross-sectional area of the tubing is at least 4:3, and wherein the ratio of the length
of the tubing to the leogth of the primary drying chambet is at least 2:1.
5 in one embodiment, the apparatus also includes a particle concentratian means,
such as a cyclone separetor, to separate and remove at least a portion of the drying gas
from the particles, wherem the particle concentration means has a particle discharge
outler in fluid communication with the inlet of the jet null.
In another embodiment, theapparatus further comprises a collection eychloae to
10 separata the drying gas from the deagglomerated or ground particles that are dischaged
from the jet mill Optionally, the apparatus includes a control valve to contcol the flow
rate of the drying gas discharged from the collection cyclone, a control valve to control
the flow rate of the drying gas discharged from the particle concentration means, or
both of these control valves.
15 In one embodiment, the apparatus further comprises a means for introducing an
excipient material into the particles and drying gas flowing between the discharge outlet
of the primary drying chamber and the inlet of the jet null. This apparatus can be used,
for example to make a dry powder blend in a single step, i.e., without intemiediate
collection and hlending steps between spray drying and jet milling.
20 In one embodiment the apparatus further comprises multiple nozzles to
introduce separate emulsions, solutions, suspensions, or combinations thereof into the
primary drying chamber. The multiple nozzles of this apparatus can be used, for
example, to introduce materials that comprise a pharmaceutical agent, an excipient, ot
combinations thereof. The multiple nozzles can be used, for example, to spray the
25 same material in order to increase the throughput or can be used to spray diffetent
materials in order to create dry powders that are mixtures of different partieles,
In another aspect, phamnacoutical compositions are provided. These
compositions comprise particles or dry podert blends mode by the spray drying and in-
line jet milling methods described herein.
Brief Description of the Drawings
FIG. 1 is a process flow diagram of one erabodiment of a process for making
mieroparticles by spraying drying with in-line jet milling to deagglomerate or grind the
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micropartieles.
FIG. 2 is a process flow diagram of one embodiment of a process for making
blends of microparticles by spray drying with in-line exeipient feeding and in-line jet
milling.
5 FIG. 3 is a cross-sectional view of a typical jet mill that can be incorpotated into
the in-line process for spray drying and jet milling.
Detailed Description of the Invention
Process systems and methods have been developed for making particles, such as
10 nricroparticles, by sptay drying and then deagglomerating or grinding the particles using
an in-line jet mill. By coupling spray drying with "in-line" jet milling, a single step
process is created from two separate unit operations, and an additional collection step is
eliminated, which otherwise would be associated with a yield loss and possible aseptic
transfer which would be undesirable for pharmaceutical production. The one-step, in-_
15 line process has further advantages in time and cost of processing. In an optional
embodiment, the systems also provide in-line blending of an excipient material with the
particles.
The jet miliing step beneficially lowers residual moisture and solvent levels in
the particles, leading to better stability and handling properties for dry powder
20 pharna ceutical formulalions or other dry powder froms comprising the partitles.
As used hertin, the tenn "in-line" refers to process equipment in fluid
comniunication arranged and adapted to process the materials in a continuous,
sequential manner. That is, the particles being processed flow between and throtigh the
individual pieces of equipment, without an intervening collection step.
25 In a preferred embodiment the particles are microparticles.
In a preferred method, the microparticles comprise one or more pharmaceutical
agents. In one embodiment, the microparticle is formed entirely of a pharmaceutical
agent In another embodiment, the microparticle has a core of pharmaceutical agent
encapsulated in a shell In yet another embodment, the pharmateutical agent is
30 interspersed within, the shell or matrix. In another embodiment, the pharmaceutical
agent is uniformly mixed within the material comprising the shell or matrix.
Optionally, the microparticles of any of these embodiments can be blended with one or
more excipients.
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As used herein, the terms "comprise," "comprising," "include," and "including"
are intended to be open, non-limiting terns, unless the contrary is expressiy indicated.
1. In-Line Methods and Apparatus making Particles
The methods include (a) spraying an emulsion, solution, or suspension, which
5 comprises a solvent and a bulk material, through one or more atomizers and into a
primaiy drying chamber having a drying gas inlet, a discharge outlet, and a dicing gas
flowing therethrough, to form droplets comprising the solvent and the bulk material,
wherein, the droplets are dispersed in the drying gas; (b) evaporating, in the primary
drying chamber, at least a portion of the solvent into the drying gas to solidify the
10 droplets and form particles dispmed in the drying gas, the particles dispersed in the
drying gas being a feedstream; and (c) flowing the particles and at least a portion of the
drying gas of the feedstream through jet null to deagglomerate or grind the particles,
in a preferred embodiment, step (c) is conducted to deagglomerate at least a, portion of
agglomerated particles, if any, while substantially maintaining the size and morphology
35 of the indiyidual particles, Alternatively, step (c) is conducted to grind the particles.
In a preferred embodiment, the feedstream of step (b) is directed through a
particle concentration means to separate and remove at least a portion of the drying gas
from the feedstream. This provides a concentration of solids in the dispersion entering
the jet mill that is high enough to permit the jet mill to operate effectively as intended,
20 i.e., to deagglomerate or grind the particles.
In another preferred embodiment, which can ne used with or without the particle
concentration means, the apparatus includes one or more secondary drying chambers
intoposed between, and in fluid communication, with, the discharge outlet of the
primary drying chamber and the inlet of the jet mill. These secondary drying chambers
25 provide additional drying of the particles, that is, they provide time and volume for
evaporation of a second portion of the solvent into the drying gas.
In yet another embodiment, which can be used with or without the particle
concentration means and with or without the secondary drying chambers, the apparatus
includes a means for introducing another material into the particles and drying-gas
30 flowing batwecn the discharge outlet of the primary drying chamber and the inlet of the
jet mill. In one embodiment, this other material could be an excipient, a second
pharmaceutical agent, or a combination thereof. For example, a diy powder beta
agonist could be introduced into a fead stream from a spray dryer that is pruducing
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microparticles containing a corticosteroid This apparatus can be used, for example, to
make a dry powder blend in a single step, i.e., without an intermediate collection step
between spray drying and jet milling.
FIG- 1 illustrates one example of an in-line system, or apparatus, 10 for making
5 and jet-milling particles. A liquid feed (i.e,, an emulsion, solution, or suspension,
which comprises a solvent and a bulk material) and an atomization gas (e.g,, air,
nitrogen, etc.) are fed through an atomizer 14. The atomized droplets of solvent and
bulk material are formed in the primary drying chamber 12. A drying gas is fed through
an optional neater 18 and into a primary drying chamber 12. In the primary drying
10 chamber, the droplets are dispersed in the drying gas, and at least a portion of the
solvenl is evaporated into the drying gas to solidify the droplets and form a feed a
feedstream of particles dispersed in the drying gas. This feedstream then exits the
primary drying chamber 12 through outlet 16 and enters (optional) secondary drying
apparatus 20, which includes a coiled tube through which the feedstream flows. Upon
15 exiting the secondary drying apparatus 20, the dispersion enters the cyclone separator
22, which serves to concentrate the particles. A portion of the drying gas is separated
from the feedstream and exits the top vent 23 of the cyclone separator 22. The
concentrated particles/drying gas then, exits the cyclone separator 22 and flows into a jet
mill 24. A grinding gas (e,g., dry nitrogen) also is supplied to the jet mill 24. The jet
20 mill 24 deagglomerates or grinds lie particles, depending, in part, on the operating
parameters selected for the jet mill, The jet-milled particles dispersed in drying gas
(and grinding gas) then flow from the jet mill 24 to a collection cyclone 26. The jet-
entiled particles are collected in collection jar 28 or other suitable apparatus, and the
drying and grinding gases are exhausted from the system 10, The exhaust gas from the
25 cyclones 22 and 26 typically is filtered (filters not shown) before release from the
system and/or into the atmosphere.
FIG. 2 illustrates one example of an in-line system, or apparatus, 40 for making
particle blends. In the embodiment shown, particles are made by spray drying, directly
blended with an excipient using an in-line excipient feed device, and then the resulting
30 bleod is Jet-miilled using an in-line jet mill, to yield a highly uniform particle blead.
The process is like that shown in FIG. 1, except an excipient material (or
pharmaceutical material or combination thereof) is added to the particles/drying gas,
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after, or more preferably before, the particles/drying gas flows through cyclone
separator 22. The resulting mixture of particles, excipient material, and drying gas then
flows into jet mill 24, where the mixture is deagglomerated or ground. The jet-milled
paricle/excipient blend dispersed in drying gas then flows from the jet mill 24 to a
5 collection cyclone 26 and collected in collection jar 28. The drying gas and grinding
gas are exhausted from system 40, as described above.
Preferably, the methods and systems are adapted for making pharmaceutical
formulations comprising microperticles, Ths microparticles are made by spray drying,
and the jet milling is effective to deagglomerate or grind the microparticles. The jet-
10 milling step can advantageously reduce moisture content and residual solvent levels in
the formulation through the addition of dry and solvent free gas directly to the jet mill
(e.g., as grinding gas). The jet-milling step also can improve the suspendability and
wettabillty of the dry powder formulation (e.g., for better injectability) and give the dry
powder formulation improved aerodynamic properties (e.g., for better pulmonary
15 delivery).
The use of a of a spray dryer wilh an in-line jet mill, as opposed to a two-step
process of a spray drying followed by a separate jet milling process, advantageously
improves yield, reduces time, and reduces cost.
Spray Drying
20 The particles are formed by a spray drying technique known in the art For
example, the particles can be produced using the spray drying methods and devices
described, for example, in U.S. Patent No. 5,853,698 to Straub et al, U.S. Patent No.
5,611,344 to Bernstein et al., U.S. Patent No, 6,395,300 to Straub et al., and U.S. Patent
No, 6,223,455 to Chickering III, et al.
25 As used herein (in the examples), the symbol "XXX" is used to indicate the term
"diameter" for the object being described.
As used herein, the term "solvent" refers to the liquid in which the material
forming the bulk of the spray dried particle is dissolved, suspended, or emulsified for
delivery to the atomizer of a spray dryer and which is evaporated into the drying gas,
30 whether or not the liquid is a solvent or nonsolvent for the material. Other volatilizable
components, such as a volatile salt, may be included in the bulk material/liquid, and
volatilised into the drying gas.
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In one embodiment, imcropaticles are produced by dissolving a pharmaceutical
agent and/or shell material in an appropriate solvent, (and optionally dispensing a solid
or liquid active agent, pore forming agent (e,g., a volatile salt), or other additive into the
solution containing the pharmaceutical agent and/or shell material) and then spray
5 drying the solution, to from microparticles. As defined herein, the process of "spray
drying" a solution containing a pharmaceutical agent and/or shell material refers to a
process wherein the solution is atomized, to form a mist and dried by direct contact with
carrier gases. Using spray drying equipment available in the art, the solution contxining
the pharmaceutical agent and/or shell material-may "be atomized into a drying chamber,
10 dried within the chamber, and then collected via a cyclone at the outlet of the chamber.
Representative examples of types of suitable atomization devices include ultrasonic,
pleasure feed, air atomizing, and totaling disk- The temperature may be varied
defending on the solvent or materials used. The temperature of the infer. and outlet
parts can be controlled to produce the desired products. Multiple nozzles (or other
15 atomization devices) can be used to allow for introduction of multiple emulsions,
solutions, suspensions, or combinations thereof into the primary drying chamber. The
multiple nozzles can be used, for example, to introduce materials that comprise a
pharmaceutical agent, an excipient, or combinations thereof, In one embodiment, the
multiple nozzles are used to spray the same materil (from each noazle) in order
20 increase process throughput of the material. In another embodiment, the multiple
nozzles are used to spray different materials (e.g., different materials from each noazle),
for example, in order to create dry powders that are mixtures of different particles, e.g.,
composed of different materials,
The size of fhe particulates of pharmaceutical agent and/or shell material is a
25 function of the nozzle used to spray the solution of the pharmaceutical agent and/or
shell material, nozzle pressure, the solution and atomization flaw rates, the
pharmaceutical agent amd/or shell material used, the concentration, of the
pharmaceutical agent and/or shell material, the type of solvent, the temperature of
spraying (both inlet and outlet temperature), and the molecular weight of a shell
30 material such as a polymer or other matrix material. Generally, if a polymer is used the
higher the molecular weight, the larger the particle size, assuming the concentration is
the same (because an increase in molecular weight generally increases the solution
viscosity). Particles having a target diameter between 0.5 um and 500 um can be
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obtained. The morphology of these wicropaticles depends, for-example, on the
selection of shell material, concentration, molecular weight of a shell material such as a
polymer or other matrix material, spray flow, and drying oonditions.
In an optional embodiment, the apparatus further includes one or more
5 secondary drying chambers downstream from the primary drying chamber to provide
additional solvent removal. In one embodiment, the secondary drying chamber
comprises the drying apparatus described in U.S. Patent No. 6,308,434 and U,S. Patent
No. 6,223,455. The secondary drying chamberpreferabry comprises fubing having an
inlet in fluid communication with the discharge outlet of the primary drying chamber, to
10 evaporole a second portion of the solvent into the drying gas, wherein the ratio of the
cross -sectional area of the primary drying chamber to the cross-sectional area of the
tubing is at least 4:3, and wberein the ratio of the length of the tubing to the length of
the primary drying chamber is at least 2:1.
Particle Concentration Means and Process Control
15 The paiticle concentration means can be essentially auy device suitable for
conentrating the particles in the drying gas such that the particles can be effectively jet
milled, whether for grinding or deaggiometation. Representative devices for
concentrating the particles in the drying gas include cyclone separators, gravity settling
chambers (knock-out pots), electrostatic charge precipitators, impingement separators,
20 mecharical centiifugal separators and uniflow cyclones.
In a preferred embodiment, the particle concentration means includes at least
one cyclone separator as known in the art, to separate and remove at least a portion of
the drying gas from said particles, In a typical embodiment, the cyclone separator
consists of a vertical cylinder with a conical bottom. The particlc/dfying gas dispersion
25 enters the cyclone through a tangential inlet near the top, entering in a vortical motion.
The centrifugal force created, causes the panicles to be thrown toward the wall, and the
drying gas folls downward along the wall and then spirals upward through the center
when it reaches the bottom, producing a double vortex. The particles fall by gravity to
the bottom of the device. One skilled in the art can select the appropriate dimensions of
30 the separator based, for example, on the flow rates of gas and particles, percentage of
gas to be separated, system pressures, particle mass and size, etc.
For a particular system, successful operation requires balancing of the flows and
pressures in the process -equipment, such that jet mill performance is maximized,
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particle blowhack from the jet mill is avoided, and clogging of the cyclone and/or jet
mill is avoided. For example, as shown in FIG. 1 and FIG- 2, control of the flow
through the system 10 or system 40 can be performed with the use of a control valve 30
downstream from the collection eyelone 26 and/or a control valve 32 downstream from
5 the separator cyclone 22, eithe or both of which can be used to conrol the pressure on
the systems. For example, by increasing the backpressure on the system, more drying
gas can be separated and expelled through the top vent of the cyclone separator.
Altermatively, less drying gas can be directed through the top vent of the cyclone
separator by lowering the backpressure on the system. Alternatively, the drying gas
10 exhusted through the cyclone separator can be in part or entirely redirected into the
system downstream of the jet mill outlet Optionally, fresh gas can be added into the
system downstream of the jet mill outlet. Such redirected or added gases can be used to
balance pressures in the process.
While a control valve is shown in FIGS-1 and 2, other flow controniug devices
25 known in the art can be used to control the system pressure and/or flow rats of drying
gas dischaiged from the particle concentration means or the collection cyclone. For
example, the flow controlling devices could comprise a device selected from control
valves, fillers, regulatore, orifices, and combinations thereef.
In one embodiment, the solids content of the feedstream (particles/drying gas)
20 from the primary and secondary drying chambers is increased by separating aut between
about 50 and 100 vol.%, more preferably about 90 and 100 vol,%, of the drying gas,
which is expelled through top vent 23. For example, in one embodiment, the flow rate
of the particles/drying gas from the apray dryer is52CFM (1500 L/min.) and the flow
rate of the particles/drying gas to the jet mill is 0.52 CFM (15 L/nim ). The system
25 components would be sized to maintain the appropriate gas velocity throughout the
process.
Jet Milling
As used herein, the terms "jet nill" and "jet milling" include and refer to the use
of any type of fluid energy impact mills, including spiral jet mills, loop jet milk,
30 hammer mills, grinders, crushers, and fludized bed jet mills, with or without internal
air classifiers. These mills are known in the art. The jet mill is used to deagglomerate
or to grind the particles.
As used herein, the term "deagglomerate" refers to the technique for
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albstaotially degglomerating micmparticle agglomerates that have been produced
during or subsequent to fomation of the microparticles, by bombarding the feed
particles with high velocity air or other gss, typically in a spiral or circular flow. The
jet milling process conditions can be selected so that the inucroparticles are substantially
5 deagglomerated while substantially maintaining the size and morphology of the
individual microparticles, which can be quantified as providing a volume average size
reduction of at least 15% and a number average size reduction of no more than 75%.
As used herein, the terms "grind", "ground", or "grinding" refers to particle size
reduction by fracture, e.g., conventional milling. That is, the particles and/or
10 agglomerates are induced in size without substantially maintaining the size and
morphology of the individual microparticles. The process is characterized by the
acceleration of particles in a gas stream to high velocities for impingement on other
particles, similarty accelerafed, or impingement on the walls of the mill.
A typical spiral jet mill 50 is illustrated in FIG. 3. Particles, with or without
15 drying gas, are fed into feed chute 52. Optional injection gas is fed through one or
more ports 56. The particles are forced through injector 54 into chamber 58. The
particles enter an extremely rapid vortest in the chamber 58, where they collide with one
another until snall enough to become sufficiently entrained in the gas stream, to exit a
central discharge port 62 in the jet mill by the gas stream (against centrifugal forces
20 experienced in the vortex). Grinding gas (so-named whether the jet mill is used for
grinding or deagglomeration) is fed from port 60 into gas supply ring 61. The grinding
gas then is fed into the chamber 58 via a plurality of apertines; only two 63a and 63b
are shown. Gnouad or deagglomerated pertictes are discharged from the jet mill 50.
The selection of the material forming the bulk of the particles and the
25 temperature of the particles in the jet mill are among the factors that affect
deagglomeration and grinding. Therefore, the jet mill optionally can be provided with a
temperature control system For example, the control syston may liest the particles,
rendering the material less brittle and thus less easily fraetured in the jet mill thereby
manimizing unwanted, size reduction. Alternatively, the control system rnay need to
30 cool the particles to below the glass transition or melting temperature of the material, so
that deagglomeration is possible.
In a preferred embodiment, the particles are aseptically fed to the jet mill, and a
suitable gas, preferably dry nitrogen, is used to process the microparticks through the
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WO 2004/060547 PCT/US2003/037108
mill. Grinding and mjection gas pressures can be adjusted as need, for example, based
on the material characteristics. Preferably, these gas pressures are between 0 and 10
bet, more preferably between 2 and E bar. Particle throughput depends on the size and
capacity of the jet mill. The jet-milled particles can be collected by filtration or, more
5 preferably, syclone,
Jet milling the particles, in addition to providing the desired level of
deagglomeration ot grinding, can also lower the residual solvent and moisture levels in
the particles or particle blend while in process (i.e., before collection), due to the
addition of dry and solvent free gas (e.g., as grinding gas, injection gas. or both)
10 provided to the jet mill. To achieve reduced residual levels, the injection/grinding gas
preferably is a low humidity gas, such as dry nitrogen, In one embodiment, the
injection/grinding gas is at a temperature less than 100 oC (e.g., less than 75 °C, less
than 50°C, less than 25 °C, etc.).
Blending
15 In an optional embodiment, the process further includes blending the particles
with another material (e.g., an excipient material, a (second) pharmaceutical agent or a
combination thereof), which can be in a diy powder form. The blending can be
performed before jet milling as an in-line process, after jet mil1ing, ot both before and
after jet milling.
20 In a preferred embodiment, the blending is conductsd in a single step process,
such as an in-line process, as shown for example in FIG. 2. This process comprises
spray drying with in-line blending and in-line jet milling. The excipient material
preferably is added to the feedstream before it flows into the jet mill. The excipient
material can be introduced into the feedstream using essentially any suitable
25 introduction means known in the ari. Non-Iimiting examples of such introduction
means include screw or vibratory feed from a closed hopper, a venhin feed from a
vented hopper, via a feedstream from one or more other spray drying units making the
excipient particles, or via a feedstream trom one or more jet milling devices, One
skilled in the art can readily conned a feed source line using standard techniques and
30 provide the excipient feed material at a sufficient pressure to cause the material to flow
into and combine with the drying gas and particles.
In another embodiment, the excipient material is blended with the particles post-
jet milling, in a batch or continuous process, including an in-line process. The blending
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WO 2004/060547 PCT/US2003/037108
can be carried out using essentially any technique or device suitable for combining the
microparticles with one or more other materials (e.g., excipients), preferably to achieve
uniformity of blend.
Content uniformity of solid-solid pharmaceutical blends is critical. Jet milling
5 can be conducted on the micropaiticles before blending or as part of a single process
(spray drying with in-line blending and in-line jet milling) to enhance content
uniformity. Jet-milling advantageously can provide improved wetting and dispersibility
upon reconstitution of fee blends, in addition, the resulting micropaiticle formulation
can provide improved injectability, passing through the needle of a syringe more easily.
10 Jet milling can provide improved dispersibility of the dry powder, which provides for
improved aerodynamic properties for nasal or pulmonary administration.
Other Steps in the Process
The particles may undergo additional processing steps. Representative
examples of such processes include Iyophilization or vacuum drying to further remove
15 residual solvents, temperature conditioning to anneal materials, size classification to
recover or remove certain fractions of the particles (i.e., to optimize the size
distribution), compression molding to form a tablet or other geometry, and packaging.
In one embodiment, oversized (e.g., 20 um or larger preferably 10 um or larger)
microparticles are separated from the microparticles of interest Some formulations
20 also may undergo sterilization, such as by gamma irradiation.
IL The Partieles
The particles made by the processes described herein comprise a bulk material.
As used herein, the term "bulk material" includes essentially any material that can be
provided in a solution, suspension, or emulsion, and then fed through, an atomizer and
25 dried to form particles. In preferred embodiments, the bulk materiai is a pharmaceutical
agent, a "shell material, or a combination of a pharmaceutical agent and a shell material,
as described herein.
Size and Morphology
The particles made by the in-line spray drying and jet mill process can be of any
30 size. As used herein, the term "particle" includes micro-, submicro-, and macro-
particles. Generally, the particles ate between about 100 nm and 5 mm in diameter or
in the longest dimension. In a preferred embodiment, the particles are microparticles,
which are between 1 and 999 microns in diameter or in the longest dimension. As used
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WO 2004/060547 PCT/US2003/037108
herein, the term "microparticle" includes microspheres and mictocapsules, as well as
microparticles, unless otherwise specified. Microparticles may or-may not be spheritical
in shaps. Microcapsules are defined as microparticles having an outer shell
sunotinding a core of another material, such as a pharmaceutical agent. The core can
5 be gas, liquid, gel, or solid, Microspheres can be solid spheres or can be porous and
include a sponge-like or honeycomb structure fonned by pores or yoids in a matrix
material or shell.
As used herein, the teams "size" or "diameter" in reference to particles refers to
the number average particle size, unless otherwise specified. An example of an
10 equation that can be used to describe the number average particlc size is shown below:

where n = number of parucles of a given diameter (d).
As used herein, the term "vohime average diameter" refers to the volume
weighted diameter average. An example of equations that can be used to describe the
15 volume average diameter is shown below:

where n — number of particles of a given diameter (d).
As used herein, the term "acrodynamic diameter" refets to the equivalent
diameter of a sphere with density of 1 g/mL were it to fall under gravity with the same
20 velocity as the particle analysed. Aerodynamic diameters can be determined on the dry
powder using an Aerosizer (TSI), which is a time of flight technique, or by cascade
impaction or liquid impinger techniques.
Particle size analysis can be performed on a Coulter counter, by light
microscopy, scaning electron microscopy, transmittance eletron microscopy, laser
25 diffraction methods such as those using a Malvem Mastersizer, light scattering methods
or time of flight methods. Where a Coulter method is described, the powder is
dispersed in an electrolyte, and the resulting suspension analyzed using a Coulter
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WO 2004/060547 PCT/US2003/037108
Multisizer II fitted with a 50-um aperture tube,
In one embodiment, the jet milling proccess described herein can deagglomerate
agglomerated particles, such that the size and morphology of the individual particles is
substantially maintained That is, a comparison of the particle size before and after jet
5 milling should show a volume average size reduction of at least 15% and a number
average size reduction of no more than 75%. It is believed that the jet milling processes
will be most useful in deagglomerating particles having a volume average diameter or
aerodynamic average diameter greater than about 2 um.
In one embodiment, the particles are micioporticles comprising a
10 pharmaceutical agent tor use in a pharmaceutical formulation. These mieroparticles
preferably have a number average size between about 1 and 10 um . In one
embodiment, the microparticles have a volume average size between) 2 and 50 um. In
another embodiment, the inicroparticles have an aerodynamic diamater between. 1 and
50 um.
15 The pharmaceutical agent containing paitides typically are manufactured to
have a size (i.e., diameter) suitable for the intended route of adminisitration. Particle
size also can affect RES uptake. For intravascular administration, the particles
preferably have a diameter of between 0,5 and 8 um, For subcutaneous or
intramuscular administration, the particles preferably have a diameter of between about
20 1 and 100 um. For oral administration for delivery to the gastrointestinal tract and for
aplication to other lumens or inucosal surfaces (eg.., rectal, vaginal, buccal, or nasal),
the particles preferably have a diameter of between 0,5 um and 5 mm. A preferred size
for administration to the pulmonary system is an aerodynamic diameter of between 1
and 5 um, with an actual volume average diameter (or an aerodynamic average
25 diameter) of 5 um or less.
In one embodiment, the particles comprise microparticles having voids therein.
In one embodiment, the microparticles have a number average size between 1
and 3 um and a volume average size between 3 and 8 um.
Pharmaceutical Agents
30 The pharmaceutical agent is a therapeutic, diagnostic, or prophylactic agent.
The pharmaceutical agent is sometimes iefened to herein generally as a "drug" or
"active agsnt" The phannaceutical agent in the fwal powder may be present in an
17

WO 2004/060547 PCT/US2003/037108
amorphous State, a crystalline state, or a mixture thereof,
A wide variety of drugs can be loaded into the micropartrcles, These can be
small motecules, proteins or peptides, carbohydrates, aligosaocharides, nucleic acid
molecules, or other synthetic or natural agents. Examples of suitable drugs include the
5 classes and species of drugs described in Martindale, the Exira Phormcopoeia, 30th
Ed. (The Pharmaceutical Press, London 1993). The drug can be in any suitable form,
including various salt forms, free acid forms, free base forms, and hydrates.
In one embodiment, the pharmaceutical agent is a contrast agent for diagnostic
imaging. For example, the agent could be a gas for ultrasound imaging, as described
10 for example in U.S. Patent No. 5,611,344 to Bernstein et al. Other examples of suitable
diagoostic agents useful herain include those agents known in the art for use in positron
emission tomography (PET), computer assisted tomography (CAT), single photon
emission computerized tomography, x-ray, fluoroscopy, and magnetic resonance
imaging (MRI).
15 In other embodiments, the pharmacentical agent is a therapeutic or prophylactic
agent Non-limiting examples of these agents include water soluble drugs, such as
ceftriaxone, ketoeonsizole, ceftazidime, oxaprpzin, albuterol, valacyclovir,
urofollitropin, famciciovir, flutamide, enalapril, mefformin, itraconazole, buspirone,
gabspentin, fosinopril, tramadol, acarbose, lorasepau, follitropin, glipizide, omeprazole,
20 fluoxetine, lisinopril, tramsdol, levofloxacin, zafirlukast, interfcion, growth hormone,
illterieukin, erythropoietin, granulocyte stimulating factor, ruzatidine, bupropion,
perindopril erbumine, adenosine, alendronate, alprostadil, benazeprel, betaxolol,
hloomycin sulfate, dexfenfluramine, diltiazom, fentanyl, flecainid, gemeilabine,
glatimmer acetate granisetron, lamivudine. mangafodipir trisodium mesalamine,
25 nietoprolol fomarate, metronidazole, mightol, moeripril, monteleukasl, ocuteotide
acctate, olopatadine, paricalcitol, somatropin, sumetriptan succinate, tacrine, verapamil,
nabumetone, trovafloxacin, dolasetron, zidovudine, froasteride, tobramycin, isradipine,
tolcapone, enoxaparin, fluconazote, lansoprazole, terbinafine, pamidronste, didanosine,
diclofenac, clsapride, venlafexine, troglitezone, fhivastatin, losartan, imiglucerase,
30 donepezil, olanzapine, valsartan, fexofenadine, calcitonin, or ipratropium bromide.
Other examples include hydrophobic drugs such as celecoxib, rofecoxib,
paclitaxel, docetaxel, acyclovir, alprazolam, amiodaron, amoxicillm) anagrclide,
aripiprazole, bactrim, biaxin, budesonide, bulsulfen, carbamazepine, ceftazidine,
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WO 2004/060547 PCT/US2003/037108
cefprozil, ciprofloxicin, clarithromycin, clozapine, cyclosporine, diazepam, estiadiol,
etodolac, famcictovir, fenofibiate, fexofenadine, gemcitabine, genclovir, itrecronazole,
lamotrigine, loratidine, lorazepatn, meloxicam, mesalamine, mitiocyclime, modafinil,
nabumetone, nelfinavir mesylate, olanzapine, oxcarbazepine, phenytoin, propofal,
5 ritinavir, risperidone, SN-38, sulfarometuoxazoI, sulfasalazine, tacrolirous, tiagabine,
tizamdine, trimethoprim, valium, valsartan, voriconazule, zafiriukast, zileuton, and
aiprasidone. In this embodiment, the partieles made by the processes destribed heirein
preferably are porous.
In One embodiment, the pharmaceutical agent is for pulmonary administration.
10 Non-limiting examples include corticosteroids such as budesonide, fluticasone
propionate beclomcthasone diptopionate, mometasone, flumisolide, and triamcicolone
acetonide; other steroids such as testosterone, progesterone, and estradiol; leukotriene
inhibitots such as zafirlukast and zileuton; antibiotics such as cefprozil, amoxicillin;
antifoogals such as ciprefloxscri, and itraconazole; hronchodilators such as stbuterol,
15 formoterol and salmeterol; snoneoplsstics such as pachtaxel and docetaxel; and
peptides or proteins such as insulin, calcitonin, leuprolide, granulocyte colony-
stimuiating factcr, porathyroid bonrmone-related peptide, and somatostatin
Examples of preferred drugs. include aripirazole, tisperidone, albuterol,
adapalene, doxazosin mesylatf, mometasone furoate, ursodiol, amphotericin, enalapril
20 maleale, felodipine, nefazodone hydrochloride, valrubicin, albendazole, conjugated
estrogens, medtoxyprogesterone acetate, nicandrpine hydrochloride, zolphdem tartrape,
amlodjpine besylatate, ethinyl estradinl omeprazole, rubitiecan, amlodipine besylate/
benazepril hydrochloride, etodolac, paroxetine hydrochloride, paclitaxel atovaquone,
felodipine, podofilor, paricalcitol, betamethasone dipropionate, fentanyl, pramiperole
25 dihydrochloride, Vitanun D, and related analogues, fmasteride, quetiapine fumarate,
alpresiacil, candesartan, cilexetil, fluconazole, ritonavir, busulfan, cartramazepine,
flumazenil, nsperidonc, carbemazepine, carbidopa,levodapa, ganciclovir, saquinavir,
amprenavn, carboplatin, glyburide, settraline hydrochloride, roferoxib carvedilol,
halobetasolproprionate, sildenafil citrate, oelecoxib, chlorthalidone, imiquitnod,
30 simvastatin, citalopran, cipofloxacin, irinolecan hydrochloride, spartloxacin,
efavirenz, cisapride monobydrate, lansoprazole, tamsulosin hydrochloride, mofafinil,
clarithromycin, letrozole, terbinafine bydrochloride, rosiglitazone maleate, diclofernac
sodium, lomefloxacin hydrochloride, tirofiban hydrochloride, telmisartan, diazapam,
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WO 2004/060547 PCT/US2003/037108
lorafadine, toremifefene citrate, thalidortude, dinoprosione, mefloqume hydrocbloride,
trandolspril, docetaxel, initoxantrone hydrocchloride, tretinoin, etodolac, triamcinolone
aoetate, estradiol, ursodiol, nelfinavir mesyiate, indinavir, beciomethasone dipropionate,
oxaprozin, flutamide, famotidine, nifedipine, prednisone, cefuroxime, lorazepam,
5 digoxin, lovastatin, griseofulvin, naproxen, ibuptofen, isotretimoin, tamoxifen citrate,
nimodipine, amiodarone, budestmide, formoterol, flucusone propionates saimeterol, and
Shall Material
The shell material can be a synthetic material or a natural material. The shell
10 uiareriai can be water soluble or water insoluble. The particles can be fomed of non-
biodegradable or biodegradable materials, although biodegradable materials are
preferred, particularly for parenteral administration. Examples of types of shell
materials include polymers, amino acids, sugars, proteins, carbohydrates, and lipids,
Polymeric shell materials can be degradable or non-degradable, crodible or non-
15 erodible, natural or synthetic. Non-erodible polymers may be used for oral
administration. In general, synthetic polymers are preferred due to more reproducible
synthesis and degradation, Natural polymers also may be used Natural biopolymers
that degrade by hydrorysis, such as polyhydroxybutyrate, may be of particular interest.
The polymer is selected based on a variety of perfonrmance factors, including the time
20 required for in vivo stabihty, i,e,, the time required for distribution to the site where
delivery is desired, and the time desired for delivery. Other salection factors may
include shelf life, degradstion rale, mechanical properties, and glass transition
temperature of the polymer.
Representative synthetic polymers include poly(bydroxy acids) such as
25 poly(lactic acid), poly(glycolic acid), and poly(lactic acid-co-glycolic acid),
poly(lactide), poly(glycolide), poly(lactide-co-glycolide), poiyanhydrides,
polyorthoester, polyamides polycarbonates polyalkylenes such as polyethylene and
polypropylene, polyalkylene giycols such as poly(ethylene glycol), polyajkylene oxides
such as poly(ethylcne oxide), polyalkylene terepthalatets such as polyethylene
30 terephthalate), polyvinyl alcohols, polyviayl ethers, palyvinyl esters, polyvinyl balides
such as poly(vitiyl chloride), palyvinytpyrrotidone. polysiloxaues, poly(vinyl alcohols),
poly( vinyl acete),polystyrene, polyurethanes and co-polymers thereof, derivativized
celluloses such as alkyl cellulose, hydroxyalkyl celluloses, cellulose ethers, cullulose
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WO 2004/060547 PCT/US2003/037108
estas, nitra celluloses, methyl cellulose, ethyl cellulose, hydroxypropyl cellulose,
hydroxy-propyl methyl cellulose, hydroxybutyl methyl cellulose, cellulose acetate,
cellulose propionate, cellulose acetate butycate, cellulose acetate ptathalate,
carhoxyethyl cellulose, cellulose triacetate, and cellulose sulphate sodium salt jointly
5 referred in herein as "synthetic celloloses"), polymers of acrylic acid, methaciylic acid
or copolymers or derivatives thereof including esters, poly(methyl methacrylste),
poly(ethyl methacrylate), poly(butyImethacrylate), poly(isobutyl methocrylate),
poly(hexylmethacrylate), poly(isodecyl methacrylats), poty(lauryl methacrylate),
poly(phenyl methacrylate), poly (methyl acrylate), poly(isopropyl acrylate),
10 poly(isobutyl acrylate), and poly(octadecyl acrylate) (jointly referred to hercin as
"polyacrylic acids"), poly(butyric acid), poly(vileric acid), and poly(lactide-co-
caprolactone), copolymers and blends thereof. As used herein, "derivatives"include
polymets having substitutions, additions of chemical groups, for example, alkyl,
altylene, hydroxylations, oxidations, salt formations, and other modifications routinely
15 made by those skilled in the art.
Examples of preferred biodegradable polymers include polymers of hydroxy
acids such as lactic acid and glycolic acid, and copolymers with PEG, polyarhydrides,
poly(ortho)esters, polyurcthanes, poly(butyric acid), poly(valeric acid), poly(lactide-co-
csprolaetone), blends and copolymers thereof.
10 Examples of preferred natural polymers include proteins such as albumin and
prulamines, for example, zein, and polysaccharides such as alginate, cellulose and
polyhydroxyalkanoates, for exarnple, polyhydrxybutyrate, The in vivo stability of the
matrix can be adjusted during the production by using polymenrs such as polylactide-co-
glycolide copolynierized with polyethylene glycol (PEG), PEG, if exposed on the
25 external surface, may extend the time these materials circulate, at it is hydrophilic and
has been demonstrated to mask RES (reticuloendothehal system) recognition.
Examples of preferred non-biodegradable polymers include ethylene vinyl
acectate, poly(meth)acrylic acid, polyamides, copolymers and mixtures thereof.
Bioadhesive polymers of particular interest for use in targeting of mucosal
30 surfaces incluls polyarihydrides, polyacrylic acid, poly(methyl methacrylates),
poly(ethyl methacrylates), poly(butylmethacrylate), poly(isobutyl methacrylate),
poly(hexylmethacrylate), poly(isodecyl inethacrylate), poly(lauryl methacrylate),
poly(phenyl methacrylate), poly(methyl acrylate), poly(isopropyl acrylate),
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WO 2004/060547 PCT/US2003/037108
poly(isobutyl acrylate), and poly(octadecyl acrylate).
Representative amino acids that can be used in the shell include both naturally
occurring and non-naturally occurring amino acids. The amino acids can be
hydraphobic or hydrophilic and may be D amino acids, L amino acids or racemic
5 mixtures. Amino acids that can be used include glycine, arginine, histidine, threonine,
asparagine, aspartic acid, serine, glutamate, proline, cysteme, methionine, valine,
leucine, isoleucine, tryptophan, pheaylalanine, tyrosine, lysine, alanine, and giutanine.
The amino acid can be used as a bulking agent, or as an anti- crystallization agent for
drugs in the amorphous state, or as a crystal growth inhibitor for drags in the crystallins
10 state or as a wetting agent. Hydrophobic amino acids such as leucine, isoleucine,
alanine, glucine, "valine, proline, cysteine, inethionine, phenylalanine, tryptophan are
more likely to be effective as anticrystallization agents or crystal growth inhibitors, In
addition, amino acids can serve to make the shell have a pH dependency that can be
used to influence the pharmaceutical properties of the shell such as solubility, rate of
15 dissolution or wetting.
The shell material can be the same or different from the excipient material, if
present In one embodiment, the excipient can comprise the same classes or types of
material used to form the shell. In another embodiment, the excipient comprises one or
more materials different from the shell material In this latter embodiment, the
20 excipient can be a surfactant, wetting agent, salt, bulking agent, etc. In one
embodiment, the formulation comprises (i) microparticles that have a core of a drug and
a shell comprising a sugar or amino acid, blended with (ii) another sugar or amino acid
that functions as a bulking or tonicity agent
Excipients
25 For particles to be used in pharmaceutical applications, the term "excipient"
refers to any non-active ingredient of the formulation intended to facilitate delivery and
administration by the intended route. For example, the excipient can comprise amino
acids, sugars or other carbohydrates, starches, surfactants, proteins, Iipids, or
combinations thereof. The excipient may enhance handling, stability, aerodynamic
30 properties and dispersibility of the active agent
In preferred embodiments, the excipient is a dry powder (e.g., in the form of
microparticles), which is blended with drug microparticles. Preferably, the-excipient
microparticles are larger in size than the pharmaceutical micro-particles. In one
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WO 2004/060547 PCT/US2003/037108
embodiment, the excipient microparticles have a volume average size between about 10
and 1000 um. preferably between 20 and 200 um, more preferably between 40 and 100
Representative amino acids that can be used in the drug matrices include both
5 naturally occurring and non-naturally occurring amino acids. The amino acids can be
hyckophobic or hydroplulic and may be D amino acids, L amino acids or racemic
mixorres. Non-limiting examples of amino acids that can be used include glycine,
argmme, histidine, threanine, asparagus aspartic acid, serine, glulamate, proline,
cysteine methionine, valine, leucine, isoleucine, tryptophan, phenylalanine, tyrosine,
10 lysine, elanine, glutamine. The ammo acid can be used as a bulking agent, or as a
crystal growth inhibitor for drugs in the crystalline state or as a wching agent
Hydrophobic amino acids such as leucine, isoleucine, alanine, glucine, valine, proline,
cysteine, methionine, pnenylalamine, tryptophan are more likely to be effective as
crystal growth inhibitors, In addition, amino acids can serve to make the matrix have a
15 pH dependency that can be used to influence the pharmaceutical properties of the
matrix such as solubility, rate of dissolution, or-wetting.
Examples of excipients include pharmaceutically acceptable carriers and
bulking agents, including sugars such as lactose, mannitol, trehalose, xylitol, sorbitol,
dextran, sucrose, and fructose. Other suitable excipients include aurface active agents.
20 dispersants, osniotic agents, binders, disintegrants, glidants, dilucuts, color agents,
flavoring agent, sweeteners, and jubric-ants. Exaropies include soddium desoxycholate;
sodium dodecylsulfate; polyoxyethylcne sorbitan fatty acid esters, e.g., polyoxyethylene
20 soibitan monolaurate (TWEEN™ 20), polyoxyethylene 4 sorbitan monolaurate
(TWEEN™ 21), polyoxyethylene 20 sorbitan monopalmitate (TWEEN™ 40),
25 polyoxyethylene 20 sorbitati monooleate (TWEEN™ 80); polyoxyethylene alkyl ethers,
e.g., polyoxyelhylene 4 lauryl ether (BRU™ 30), polyoxyethylene 23 lauryl ether
(BRU™ 35), polyoxyethylenc 10 olyl ether (BRUTM 97); and polyoxyethylene glycol
esters, e.g., poloxyethylene 8 stearate (MYRJ™ 45), poloxyethylene 40 steasate
(MYRJ™ 52), Spans, Tyloxapol or mixtures thereof.
30 Examples of binders include starch, gelatin, sugars, gums, polyethylene ghycol,
ethylcellulose, waxes and polyvinylpyrrolidone. Examples of disintegrants (including
super disintegrants) include starch, clay, celluloses, croscarmnelose, crospovidonc and
sodium starch glyoolate. Examples of glidants include colloidal silicon dioxide and
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WO 2004/060547 PCT/US2003/037108
talc. Examples of diluente include dicalcium phosphate, calcium sulfate, lactose,
cellulose, kaolin, mannitol, sodium chloride, dry starch and powdered sugar. Examples
of lubricants include tale, magnesium stearate, calcium steatate, steatic acid,
hydiogenated vegetable oils, and polyethylene glycol.
5 The amounts of excipient for a particular formulation depend on a variety of
factors and can be selected by one skilled in the art Examples of these factors include
the choice of exicipient, the type and amount of drug, the micropartficle size and
morphology, and the desired properties and route of administration of the final
formulation.
10 In one embodiment for injectable microparticles, a coimbination of mannitol and
TWEEN™ 80 is tended with polymeric microspheres. In one case, the mannifol is
provided at between 50 and 200 % w/w, preferably 90 and 130 % w/w, microparticles,
while the TWEENTM 80 is provided at between 0.1 and 10 % w/w, preferably 2,0 and
5,1 % w/w microparticles. In another case the mannitol is provided with a volume
15 average particle size between 10 and 500 um.
In another emboment, the exripient comprises lactose for an inhaled dosage
form.
In yet another embodiment, the excipient comprises binders, disintegrants,
glidants, diluent color agents, flavoring agents, sweeteners, and lubricants for a solid
20 oral dosage form such as a capsule, a tablet, or a wafer,
Forparticles to be used in non-pharmaceutical applications, the term "excipient"
refers to essentially any material that can be blended with the particles for any purpose.
III, use of the Particles
Particles tnade using the processes described herecin can be used in a wide
25 vsriety of spplications and industries, including albcasives, agricultural products,
biochemical product chemicals, cosmetics, dyes, foods, metals, pigments, and
pharmacenticals. For some applications, the particles preferably are microparticles.
In a preferred embodiment, the particles are microrparticles for use in a
pharmacentical formulation, which can be administered to a human or animal in need
30 thereof, for the delivery of a therapeutic, diagnostic, or prophylactic agent in an
effective amount. The formulations can be administered in dry form or dispersed in a
physiological solution for injection or oral administration. The dry form can be
acrosolized and inhaled for pulmonary administration. The toute of administration
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WO 2004/060547 PCT/US2003/037108
depends on the pharmaceutical agent being delivered.
In one embodiment, microparticles or blends of microparticles/excipient are jet
milled to deagglomerate the particles and then further processed, using known
techniques, info a solid oral dosage from Examples of such solid oral dosage forms
5 include powder-filled capsules. lablets, and wafers, The jel-milling advantageonsly can
provide improved wetting and diapersibility upon oral dosing as a solid oral dosage
from formed from these microparticles or microparticle/excipient blends.
The invention can further be understood with refereunce to the following non-
limiting examples.
10
Example l: Spray Drying of PLGA Microspheres
Without Milling (Comparative Example)
This example describes a process for making PLGA microspberes, The
micropheres were made in a batch spray drying process. A polymer emulsion was
15 prepared, composed of droplets of an aqueous phase suspended in a continuous
polymer/organic solvent phase. The polymer was a commercially obtained
poly(lactide-co-glycolide) (PLGA) (50:50). The organic solvent was methytene
chloride. The resulting emulsion was spray dried on a custom spray dryer with a dual
drying chamber set-up. The process conditions resulted in a theoretical solids to drying
20 gas mass flow ratio of 4,77 g solids/min.; 1.6 kg nitrogen/min, The outlet temperature
of the primary drying chamber was maintained at 12 oC. The discarga of the primary
drying chsmber was connected to a custorn secondary drying chamber comprising 100
feet of 1.5" XXX coiled tubing, enveloped by a water-cooled jacket The discharge of the
secondary drying, chamber was connected to a cyclone collector having a, 1" XXX inlet, a
25 1 "XXX exthaust outler, and a 1.5" XXX dust outler. Three replicate barches were genirated
Particte size "was measured using a Coulter Multisizer II with a 50 um aprture. Table 1
presents the averages size results for the three batches.

30
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Example 2: PLGA Micr oparticles Formed Using an In-Line
Spray Drying / Jet Milling Process
PLGA microspheres were produced using a batch spray drying process with an
in-line jet mill. A polymer emulsion was prepared, composed of droplets of an aqueous
5 phase suspended in a continuous polymer/organic solvent phase. The polymer was a
commercially obtained poly(lactide-co-glycolide) (PLGA) (50:50). The organic solvent
was methylene chloride. The resulting emulsion was spray dried on a custom spray
dryer with a dual drying chamber set-up. The process conditions resulted in a
theoretical solids to drying gas mass flow ratio of 4.77 g solids/min : 1.6 kg
10 nitrogen/min The outler temperature of the primacy drying chamber was maintained at
12 oC The discharge of the primary drying chamber was connected to a secondary
drying chamber comprising 100 feel of 1.5" XXX coiled tubing, enveloped by a water-
cooled jacket. The discharge of the secondary drying chamber was connected to a
concentrating cyclone having a 1" XXX inlet, a 1" XXX exhaust outlet, and a 1.5" XXX dust
15 outlet. A 0 2 um filter was attached to each of the concentrating cyclone exhausts. A
jet mill (Hosokawa 50AS) was connected to the concentrating cyclone dust outlet using
a 1 S\ 2" short reducer. Dry nitrogen was supplied to the jet mill for grinding and
injection gas. the jet mill was operated at P1 = 3 bar and Pg = 2.9 bar. A cyclone
collector, having a 3/8" XXX inlet, a 3/4" XXX exhaust outlet, and a 3/4" XXX dust outlet, was
20 connected to, the discharge of the jet mill to collect the microspheres. A 0,2 um filter
was attached to the jet mill cyclone exhaust. This experiment was conducted in
triplicate. An average product yield of 56.5±4.2% was obtained. Particle size was
measured using the same method as in Example 1, and the average results for the three
batches are shown in "Table 2.

Table 3 provides a comparison of the average size results of the unmilled and
in-line milled microspheres from Examples 1 and 2.

WO 2004/060547 PCT/US2003/037108

This demonstrates that in-line jet milling was effective in deagglomeration.
Example3: Batch Processing of Celecoxib Microspheres (Comparative Example)
5 Celecaxib (CXB) miciospheres were produced using a batch spray drying
process. A solution containing CXB in 800 mL of methanol-water (65:35) was spray
dried on a custom spray dryer with a single drying chamber. The process conditions
resulted in a theoretical solids to drying gas mass flow ratio of 0.24 g solids/min : 1.7
kg nitrogen/min. The outlet temperature of the drying chamber was set at 20 oC The
10 discharge of the drying chamber was connected to a cyclone collector having a 1"XXX
inlet, a 1 " XXX exhaust outlet, and a 1.5" XXX dust outlet
Duplicate batches were generated. Yield was calculated as the mass of dry
product divided by the dry mass of non-volatile masterials in the feed stock. Geometric
particle size (volume mean) was measured using an Aerosizer particle sizer set at both
15 high shear and zero shear. Table 4 presents the yield and size insults for the two
batches.

The powder from Experiment No, 3.1 was fed manually into a Fluid Energy
20 Aljet Jet-O-Mizer jet mill at a feed rate of about 1 g/min. Dry nitrogen gas was used to
drive the jet mill The operating parameters were 4 bar grinding gas pressure and 8 bar
injection gas pressure. A cyclone collector, having a 3/8" x 3/4" rectangular inlet, a 3/4"
XXX exhaust outlet, and a 1/2" XXX dust outlet, was connected to the discharge of the jet mill
to collect the microspheres. Yield and particle size were measured using the same
25 methods as described above within the Example. Table 5 compares the results of the
pre-milled material (Experiment No. 3.1) to the results of the batch jet milled material
(Experiment No. 3,3).
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WO 2004/060547 PCT/US2003/037108

The data shows that jet milling reduced the particle size of the CXB powder.
The final yield of the batch process can be calculated by multiplying the yield for
5 experiment 3.1 times the yield from experiment 3.2. This calculates to a final process
yield of 52% for the batch milled product.
Example 4: Celecoxib Microspberes Formed Usiug an In-Line Process
CXB microspheres were produced using a spray drying process with an in-line
10 jet mill. A solution containing CXB in 800 mL of methanol-weter (65:35) was spray
dried on a custom spray dryer "with a single drying chamber. The process conditions
resulted in 8 theoretical solids to drying gas mass flow iatio of 0,24 g solids/min.: 1.7
kg nitrogen/min. The Outlet temperature of the drying chamber was set at 20 oC. The
discharge of the drying chamber was connected to a concentrating cyclone harving a 1"
15 XXX intet, a 1" XXX exhaust outlet, and a 1,5" XXX dust outlet A jet mill (Fluid Energy Aljet
Jet-O-Mizer) was conneccted directly to the concentrating cyclone dust outlet Dry
nitrogen was supplied to the jet mill for grinding and injection gas. The jet mill was
operated at Pi = 8 bar and Pg = 4 bar. This experiment was carned out in duplicate,
with difienart collection cyclones used in each experiment A cyclone collector, having
20 a 3/8" x 3/4" rectangular inlet, a 3/4" XXX exhaust outlet, and a 1/2" XXX dust outlet, was
connected to the discharge of the jet mill to collect the micfospheres for Experiment
No. 4.1. A cyclone collector, having a XXX inlet, a 3/4" XXX exhaust outlet, and a 3/4"
XXX dust outlet, was connected to the discharge of the jet mill to collect the microspheres
for Experiment No. 42. The smail difference in yield between the two collection
25 cyclones used in Experiments No. 4.1 and No. 4.2 was not considered to be significant.
Yield and particle size were measured using the some methods as in Example 3, Table
6 presents the average results for the duplicate batches.

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WO 2004/060547 PCT/US2003/037108
Table 7 provides a comparison, of the average size and yield results of the unmilled,
natch milled, and in-line milled CXB microspheres from Examples 3 and 4.

5 In-line jet milling was as effective as batch jet milling in reducing particle size.
The in-line process resulted in a higher product yield (64%) than the combination of the
batch processes (52%).
Example5: Batch Processing of Paclitaxel Mirospheres (Comparative Example)
10 Paclitaxel (PXL) microspheres were produced using a batch spray drying
process. A solution containing PXL in 800 mL of etbanol-water (80:20) was spray
dried on a custom spray dryer with a single drying chamber. The process conditions
resulted in a theoretical solids to drying gas mass flow ratio of 0.83 g solids/min : 2.0
kg nitrogen/min. The outlet temperature of the drying chamber was set at 57 oC, The
15 discharge of the drying chamber was connected to a cyclone collector haying a 1" XXX
inlet, a 1" XXX exhaust outlet, and a 1-5" XXX dust outlet.
One batch was geuerated Yield was calculated as the mass of dry product
divided by the dry mass of non-volatile materials in the feed stock. Geometric particle
size (volume mean) was measured using a Mastersizer particle size analyzer set at
20 maximum pressure. Table 8 presents the yield and size results.

The powder from Experiment No. 5.1 was fed manually into a Fluid Energy
Aljet Jet-O-Mizer jet mill at a feed rate of about 1 g/min. Dry nitrogen gas was used to
25 drive the jet mill. The operating parameters were 4 bar grinding gas pressure and 8 bar
injection gas pressure. A cyclone collector, having a 3/8" XXX inlet, a 3/4" XXX exhaust
outlet, and a 3/4" XXX dust outlet, was connected to the discharge of the jet mill to collect
the mitrospheres. Yield and particle size were measured using the same methods as
described above within the Example. Table 9 compares the results of the pre-milled
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WO 2004/060547 PCT/US2003/037108
material (Experimeat No. 5.1) to the results of the batch milled material (Experiment
No. 5.2).

5 The data shows that, in this case, batch jet milling did not significantly change
the particle size of the PXL powder. The final yield of the batch process can be
calculated by multiplying the yield for Experiment No. 5,1 times the yield from
Experiment No. 5.2, This calculates to a final process yield of 49% for the batch milled
product.
10
Example 6: Paclitaxel Microspheres Formed Using an In-Line Process
PXL microspheres were produced using a spray drying process with an in-line
jet mill. A solution containing PXL in 800 mL of ethanol-water (80:20) was spray
dried on a custom spray (dryer with a single drying chamber. The process conditions
15 resulted in a theoretical solids to diying gas mass flow ratio of 0,83 g solids/min; 2.0
kg nitrogen/min. The outlet temperature of the drying chamber was set at 57 oC. The
discharge of the diying chamber was connected to a concentrating cyclone having a I"
XXX inlet, a 1" XXX exhaust outlet, and a 1.5" XXX dust outlet. A jet mill (Fluid Energy Aljet
Jet-O-Mizer) was connected directty to the concentrating cyclone dust outlet Dry
20 nitrogen was supplied to the jet mill for grinding and injection gas. The jet mill was
operated at P; = 8 bar and Pg = 4 bar. A cyclone collector, having a 3/8" XXX inlet, a 3/4"
XXX exhaust outlet, and a 3/4" XXX dust outlet, was connected to the discharge of the jet mill
to collct the microspheres for Experiment No. 5.1. Yield and particle size were
measured using the same methods as in Example 5. Table 10 presents the results.

Table 11 provides a conipari&on of the average siae and yield results of the unmiUed,
batch imilled, and in-line milled PXL raicrospheres from Examples 5 and 6.
30

WO 2004/060547 PCT/US2003/037108

In-line-jet milling was more effective than batch jet milling in reducing particle
size. The in-line process resulted in a higher product yield (66%) than the combination
5 of the batch processes (45%).
Example 7: PLGA Micropartictes formed, Blended with Mannitol/Tween 80,
And Jet Milled Using an In-Line Process
PLGA microspheres were produced using a single in-line process involving
10 spray drying, blending with mannitol/Tween 80 powder, and jet-milling using the
Hosokawa 50AS jet-mill. A polymer emulsion was prepared, composed of droplets of
an aqueous phase suspended in a continuous polymer/oranic solvent phase. The
polymer was a commercially obtained poly(lactide-co-glycolide) (PLGA)(50:50). The
organic solvent was methylene chloride. The resulting eniulsion was spray dried on a
15 custom spray dryer with a dual drying chamber set-up, The mannitol/Tween 80 powder
was injected at the discharge of the secondary drying chamber (which is upstream from
the concentrating cyclone having a I" XXX inlet, a 1" XXX exhaust outlet, and a 1.5" XXX dust
outlet) using a nitrogen feed. The dust outlet of the concentrating cyclone was
connected to the inlet of the jet-mill. Another cyclone collector, baying a 1" XXX inlet, a
20 1" XXX exhaust outlet, and a 1.5" XXX dust outlet, was connected to the discharga of the jet-
mill to collect the product.
The experiment was conducted in duplicate. The particle size of the product
obtained from this experiment is given in Table 12.

Three samples from Experiment No. 7.1 were reconstituted with 5 ml of RO/DI water,
which dissolved the mannitol/Tween 80 powder The microsphere mass for each vial
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WO 2004/060547 PCT/US2003/037108
was determined by filtering the reconstituted suspension and collecting the undissoived
microspheres on the filter. The mess of mamitol/Tween 80 was determined by
lyophilizing the filtered solution. The results are given in Table 13.

The relative standard deviation (R.S.D) values horn the Table 13 indicate that it was
possible to achieve a uniform blend through an in-line process involving.spray drying,
blending, and jet milling.
Publications cited herein and the meterials for which they are cited are
10 specifically incorporated by reference. Modifications and variations of the methods and
devices described herein will be obvious to those skilled in the art from the foregoing
detailed description. Such modifications and variations are intended to come within the
scope of the appended caims.
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We claim:
1. A method for making particles comprising:
(a) spraying an emulsion, solution, or suspension, which comprises a
solvent and a bulk material, through at least one atomizer and into a primary drying
chamber having a drying gas inlet, a discharge outlet, and a drying gas -flowing
therethrough, to form droplets comprising the solvent and the bulk material, wherein the
droplets are dispersed in the drying gas;
(b) evaporating, in the primary drying chamber, at least a portion of the
solvent into the drying gas to solidify the droplets and form particles dispersed in the
drying gas, the particles dispersed in the drying gas being a feedstream; and
(c) flowing the feedstream through an in-line jet mill to deagglomerate or
grind the particles.
2. The method of claim 1, wherein before step (c), the feedstream of step (b) is
directed through a particle concentration means to separate and remove at least a portion
of the drying gas from the feedstream.
3. The method of daim 2, wherein the particle concenrration means comprises a
cycl one separator,
4. The method of claim 2, wherein the particle concentration means comprises one or
more devices selected from gravity settling chambers, electrostatic charge pretipitators,
impingement separators, mechanical centrifugal separators, and uniflow cycloues.
5. The method of any of claims 2 to 4, wherein between about 50 and 100 vol% of
the drying gas is separated from the feedstream.
6. The method of claim 1, wherein, before step (c), the feedsiream of step (b) is
directed throtigh at least one secondary drying chamber in fluid communication with the
discbarge outlet of the primary drying chamber to evaporate a second portion of the
solvent into the drying gas.
33
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WO 2004/060547 PCT/US2003/037108

7. The method of claim 6, wherein the at least one secondary drying chamber
comprises tubing having an inlet an fluid cammlaucation with the discharge outlet of
the primary drying chamber, wherein the ratio of the cross-sectional area of the primary
drying chamber to the cross-sectional area of the tubing is at least 4:3, and wherein the
ratio of the length of the tubing to the length of the pritnary drying chamber is at least
2:1.
8. The method of any of claims 1 to 7, wherein step (c) is conducted to
deagglomerate at least a portion of agglomerated particles, if any, while, substantially
maintaining the size and morphology of the individual particles.
9. The method of any of claims 1 to 7, wherein step (c) is conducted to grind the
particles.
10. The method of any of claims 1 to 9, wherein the bulk material comprises a
phannacentical agent.
11. The method of claim 10, wherein the bulk material further comprises a shell
material.
12. The method of claim 11, wherein the shell material is selected from polymers,
lipids, sugars, carbotydrates, proteins, peptides, amino acids, and combinations thereof.
13. The method of any of claims 1 to 12, wherein the particles are microparticles.
14. The method of claim 13, wherein the mioroparticles comprise microspheres
having voids or pores therein.
15. The method of any of claims 1 to 14, wherein the bulk material comprison a
therapeutic or prophylactic agent
16. The method of claim 15, wherein the therapeutic or prophylactic agent is
hydrophobic and the particles comprise microspheres having voids or pores therein.
17. The method of any of claims 1 to 16, further comprising adding to the
feedstream an excipient material, aphannacenrtical agents or both.
34

14 03-2005 US0337108

PCT/US03/037108
25. A method tor making a dry powder blend comprising:
(a) spraying an emulsion, solution, or suspension, which comprises a
solvent and a bulk, material, through an atomizer and into a primary drying chamber
having a drying gas inlet, a discharge outlet, and a drying gas flowing therethrongh, to
form droplets comprising the solvent and the bulk material, wherein the droplets arc
dispersed in the drying gas;
(b) evaporating, in the primary drying chamber, at least a portion of the
sulvent into the drying gas to solidify the droplets and form particles dispersed in the
drying gas, the particles dispersed in the drying gas being a feedstream;
(c) adding a dry powder material to the feedstream to form a combined
feedstream; and
(d) flowing the combined feedstream through an in-line jet mill to
deagglomerate or grind the particles and dry powder material of the combined fcedstrcam.
26. The method of claim 25, wherein the feedstream or the combined feedstream is
direcred through a particle concenrration means to separafe and remove at least a portion,
of the drying gas from the feedstrearn or the combined feedstream, respectively.
27. The metaod of claim 25 or 26, wherein the particles are micro particles comprising
a pharmaceutical agent and the dry powder material comprises an excipient material, a
second pharmaceutical agent, or a combination thereof.
28. The incthud of claim 25 or 26, wherein the particles are microparticles comprising,
a pharmaceutical agent and the dry powder material is in the form of microparticles having
a size that is largez than the-size of the microparticles comaprising a pharmaceutical agent,
29. The method of any of claims 25 to 28, wherein step (d) is couducled to
deagglomerate at least a puilion of aggluneraled parucles, if any, while substantially
maintaining the size and morphology of the individual particles.
AO1284295.l
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PCT/US03/037108
30. An apparalus for making particles comprising:
at least one atomizer for spraying an emulsion, solution, or suspension,
which comprises a solvent and a bulk material to form droplets of the solveot and the bulk
maicrial;
a primary drying chamber having a drying gas inlet and a discharge outlet,
the atomizer being located in the primary drying chamber which provides for evaporation
of at least a portion of the solvent into the drying gas to solidify the droplets and form
particles dispersed in the drying gas; and
an in-line jet mill having an inlet to fluid commonication with the disoharge
outlet primary drying chamber, the jet mill being operable to receive the particles
dispersed in at least a portion, of the drying gas and grind or deagglomerate the particles.
31, The apparatus of claim 30, further comprising at least one secondary drying
chamber interposed between, and in fluid communication with, the discharge outlet of the
primary drying chamber and the intel of the jet mill, wherein the at least out secoudary
during chamber provides for evaporation of a second portion of the solvent into the drying
32. The apparatus of claim 31, wherein the at least one secondary drying chamber
comprises tubing having an iulet in fluid communication with the dischaige outlet of the
primry drying chamher, wherein the ratio of the cross-sectional area of the primary
drying chamber to the cross-sectional area of the tubing is at least d-3, and wherein the
ratio of the lengh of the tubing to the length of the primary drying chamber is at least 2; 1.
33. The apparatus of any of claims 30 to 32,. further comprising a particle
concentration means to separate and remove at least a portion of the drying gas from the
particles.
34. The apparatus of claim 33, wherein the particle concentration means comprises one
or more devices selected from cyclock; separatous, gravity settling chambers, electrostatic
charge precipitators, impingement separators, mechanical centrifugal separanors, and
uniflow cycloncs.
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WO 2004/060547 PCT/US2003/037108


35. The apparatus of claim 34, further comprising a flow controlling device to
control the flaw rate of drying gas discharged from the particle concentration means.
36. The apparatus of claim 30, futher comprising a coliection cyclone to separate
the drying gas from the deagglomerated or ground particles which are discharged from
the jet mill.
37. The apparatus of claim 36, further comprising a flow controlling device to
control the flow rate of the drying gas discharged from the collection cyclone.
38, The apparatus of claim 35 or 37, wherein the flow controlling device comprises
a device selected from control valves, filters, regulators, orificest and combinations
thereof.
39. The apparatus of claim 30, further comprising a means for introducing an
excipient material into the particles and drying gas flowing between the discharge outlet
of the primary drying chamber and the inlet of the jet mill.
40. The apparatus of claim 30, comprising a plurality of atomizers disposed in the
primary drying chamber.
41. A pharrnaceutical compusition comprising particles made by the method of any
of claims 1 to 24.
42. A pharmaceutical composition comprising a dry powder blend made by the
method of any of claims 25 to 29.
38

metheds and appuratur are privided for making particles comparsing (1) spraying an emulstion solution or sos-
pension, which comprise a solvent and a bult inulcnal (e.g., a phannaceuiletal agent). thought all atulpizer(14) and into a primary
Urving chamber (12) having a drying gas following therthrough, to from droplets comprising the solvent and bulk matchal dispersed
in the drying gas (b) eraporning, in the primary draying chamber (12), an loast a portion of the solvem into the drying gas to solidify
the droplets and rorm paricles dispersed in draying gas and flowing the partiles and of least a portion or the drying gas though
a jet mill (24) to deageglomerate or grind the parthcles. By coupling spray drying with "in-line" jet milling, a single step process
is ereaied from two separate unit openations. and an additional colletion step is advanlagcosty climtred. The one-step, in-line
process has further advanges in utsc and cost of proccessing.


Documents:


Patent Number 217417
Indian Patent Application Number 01086/KOLNP/2005
PG Journal Number 13/2008
Publication Date 28-Mar-2008
Grant Date 26-Mar-2008
Date of Filing 07-Jun-2005
Name of Patentee ACUSPHERE, INC.
Applicant Address 500 ARSENAL STREET, WATERTOWN, MA 02472, U.S.A
Inventors:
# Inventor's Name Inventor's Address
1 CHICKERING DONALD E, III 3 HOLLY WAY , FRAMINGHAM , MA 01701 U.S.A
2 NARASIMHAN SRIDHAR 32 BEULAH STREET, APT. 4, FRAMINGHAM, MA 01701, U.S.A
3 ALTREUTER DAVID 674 WASHINGTON STREET, APT.#1, BROOKLINE, MA 02446, U.S.A
4 KOPESKY PAUL 10 WESTON AVENUE,#211, QUINCY, MA 02170, U.S.A
5 KEEGAN MARK 55 HIGH STREET, UNIT #8, ANDOVER,MA 01810,U.S.A
6 STRAUB JULIE A 100 CAMBRIDGE STREET, WINCHESTER, MA 01890, U.S.A
7 BERNSTEIN HOWARD 33A TROWBRIDGE STREET, CAMBRIDGE, MA 02138, U.S.A
PCT International Classification Number B01J 2/04
PCT International Application Number PCT/US2003/037108
PCT International Filing date 2003-11-20
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/324,943 2002-12-19 U.S.A.